Method and apparatus for manufacturing paving and/or panelling modules

ABSTRACT

A method of manufacturing paving and/or panelling modules which comprises the steps of: arranging a plurality of blocks or tesserae in a suitable template, according to a layout predefined by a locating grid of a module; cutting a piece of a layer of flexible material provided with through openings so that it matches the configuration of the module and is larger than the module; and securing through permanent securing means, the layer of flexible material to each one of the blocks or tesserae forming a module, so that they are held together by the layer with the possibility of changing their mutual inclination.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to a method and an apparatus formanufacturing paving and/or panelling modules.

[0002] Paving by means of blocks or tesserae in a mosaic-like pattern iscurrently generally performed by manually laying a single block ortessera at a time on a sand or cement bed.

[0003] The manner in which the individual blocks are arranged creates,as a whole, ornamental patterns which reproduce geometric shapes, e.g.an arc, a circle or a compound fan, which are repeated identically anumber of times depending upon on the dimensions of the surface to becovered.

[0004] The workers assigned to laying the blocks must then be expert inthe trade, since carrying out these geometric shapes requires longworking experience and a special skill in placing the individual blocksin order to obtain the best overall results, at a fair laying speed.

[0005] A drawback of current block laying methods is therefore the factthat since they must be performed necessarily on site and by specializedpersonnel, they entail long production times and rather high laborcosts.

[0006] Another drawback of paving and/or panelling with current layingtechniques is that any detachment of a single block and/or mosaictessera leaves space for the adjacent elements to move and, in arelatively short time, detach, thereby compromising the integrity of thecomposition.

SUMMARY OF THE INVENTION

[0007] The main object of the present invention is to provide a newmethod for paving and/or panelling by means of blocks or tesserae whichdoes not necessarily involve the use of specialized labor, therebysignificantly reducing its implementation costs.

[0008] Another object of the present invention is to provide anapparatus for the mass-production of modules for street paving and/orpanelling by means of which it is possible to cover larger surfaces inless time, while making the laying operation simpler and above allfaster.

[0009] Another object of the present invention is to allow massproduction of a plurality of variously shaped modules which can bemutually assembled and are suitable for producing multiple ornamentalpatterns also for panelling sloping surfaces and vertical walls.

[0010] Another object of the present invention is to provide moduleswhich adapt themselves to the uneveness of the surface to be covered andensure integrity of the finished work, thereby preventing detachment ofsingle blocks, which would cause movement and gradual separation ofadjacent blocks.

[0011] Another object of the present invention is to provide moduleswhich, once laid, are durable and ensure particularly extendedresistance to mechanical stresses and atmospheric agents.

[0012] Another object of the present invention is to provide a pavingsystem which is permeable to, and capable of draining rainwater whilepreventing washing out of the sand from the bed.

[0013] Another object of the present invention is to provide moduleswhich can be easily lifted and carried by one operator.

[0014] According to a first aspect of the present invention, there isprovided a method for manufacturing paving and/or panelling moduleswhich comprises the following operating steps:

[0015] arranging a plurality of blocks or tesserae in a suitabletemplate, according to a predetermined layout defined by a locating griddelimiting a module;

[0016] cutting a piece of a layer of flexible material having throughopenings so as to match the configuration of said module and being oflarger dimensions than said module;

[0017] securing, by means of permanent securing means said layer offlexible material to each one of said blocks or tesserae forming saidmodule, so that they are held together by said piece of flexiblematerial with the possibility of changing their mutual inclination.

[0018] Advantageously, said method, before rigidly coupling said layerto the bottom of said blocks, includes an operation of spraying anddrying a primer onto the bottom of said blocks in order to promoteadhesion of said coupling means.

[0019] According to another aspect of the present invention there isprovided an apparatus for performing the above method, which has asupporting frame, a plurality of workstations arranged sequentially anda conveyor which extends sequentially through said workstations, and ischaracterized in that it comprises at least one moving unit designed tobe arranged on said conveyor to convey a module through each one of saidworkstations, and in that one of said workstations comprises a devicefor applying permanent coupling means, thereby coupling a piece offlexible material to the bottom of said module.

[0020] Advantageously, said moving unit comprises a movable transfertray which is designed to be arranged on said conveyor, a templatesupporting tray arranged to be located on said movable transfer tray, atleast one reference template to be fitted on said template supportingtray and a locking cover which is designed to fix the or each referencetemplate on said template supporting tray.

[0021] According to another aspect of the present invention, there isprovided at least one module for street paving and/or panelling whichcomprises at least one block or tessera, characterized in that itcomprises a layer of flexible material which has through openings andpermanent securing means for rigidly coupling said layer of flexiblematerial to the or each block.

[0022] Advantageously, said layer of flexible material provided withthrough openings comprises a meshed net.

[0023] Conveniently, said module comprises two or more of said blocks ortesserae arranged according to a predetermined composition and heldtogether by said net.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Further aspects and advantages of the present invention willbecome better apparent from the following detailed description of somecurrently preferred embodiments thereof, given merely by way ofnon-limitative example with reference to the accompanying drawings,wherein:

[0025]FIG. 1 is a plan view of an apparatus for producing aprefabricated module according to the present invention;

[0026]FIG. 2 is an axonometric view of a movable transfer tray;

[0027]FIG. 3 is an axonometric view of a template supporting tray;

[0028]FIG. 4 is an axonometric view of a locking cover;

[0029]FIG. 5 is an axonometric view of a detail of the locking cover ofFIG. 4;

[0030]FIG. 6 is a plan view of a composition shaped like a contrastingarc;

[0031]FIG. 7 is a plan view of a left module of the composition of FIG.6;

[0032]FIG. 8 is a plan view of a reference template for producing themodule of FIG. 7;

[0033]FIG. 9 is a plan view of a right module of the composition of FIG.6;

[0034]FIG. 10 is a plan view of a left initial module of the compositionof FIG. 6;

[0035]FIG. 11 is a plan view of a right initial module of thecomposition of FIG. 6;

[0036]FIG. 12 is a plan view of a left final module of the compositionof FIG. 6;

[0037]FIG. 13 is a plan view of a right final module of the compositionof FIG. 6;

[0038]FIG. 14 is a plan view of a lateral closure module of thecomposition of FIG. 6;

[0039]FIG. 15 is a plan view of a circular composition;

[0040]FIG. 16 is a plan view of a module of the composition of FIG. 15;

[0041]FIG. 17 is a plan view of a module with corner frame of thecomposition of FIG. 15;

[0042]FIG. 18 is a plan view of a module with left frame of thecomposition of FIG. 15;

[0043]FIG. 19 is a plan view of a module with right frame of thecomposition of FIG. 15;

[0044]FIG. 20 is a plan view of a composition shaped like a compoundfan;

[0045]FIG. 21 is a plan view of a left module of the composition of FIG.20;

[0046]FIG. 22 is a plan view of a right module of the composition ofFIG. 20;

[0047]FIG. 23 is a plan view of a central module of the composition ofFIG. 20;

[0048]FIG. 24 is a plan view of a left half central module of thecomposition of FIG. 20;

[0049]FIG. 25 is a plan view of a right half central module of thecomposition of FIG. 20;

[0050]FIG. 26 is a plan view of a left module of the composition of FIG.20 according to another embodiment;

[0051]FIG. 27 is a plan view of a right module which can be coupled tothe module of FIG. 26;

[0052]FIG. 28 is a plan view of a left final module of the compositionof FIG. 20;

[0053]FIG. 29 is a plan view of a right final module of the compositionof FIG. 20;

[0054]FIG. 30 is a plan view of a left lateral closure module of thecomposition of FIG. 20; and

[0055]FIG. 31 is a plan view of a right lateral closure module of thecomposition of FIG. 20.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0056] In the accompanying drawings, identical or similar parts orcomponents have been designated by the same reference numerals.Initially with reference to FIGS. 1 to 8, reference numeral 1 indicatesa generic module, the method for producing a module 1 requiring anapparatus 2 comprising a frame 3 which supports an uninterruptedconveyor 4 arranged to move a series of movable units 5.

[0057] Each movable unit 5 comprises a movable transfer tray 6, shown inFIG. 2, which is designed to slide along guides 7 of the conveyor 4 andto support a template supporting tray 8, as shown in FIG. 3.

[0058] The movable transfer tray 6 can be constituted by a squareplatform 9 which has two straight and parallel raised guides 11 on itsupper surface 10 and a vertical locating pin 12 at each one of its fourcorners.

[0059] Each locating pin 12 has a rack-shaped side or front 13 and isorientated so that its rack-shaped side is directed toward therack-shaped front of the pin located in the adjacent corner and on thesame side with respect to the guides 11.

[0060] The template supporting tray 8, shown in FIG. 3, has on its lowersurface 14 two straight and parallel grooves 15 which are designed toslide, in use, along the guides 11 of the transfer tray 6.

[0061] The template supporting plate 8 also has, at its upper surface, aperipheral rim 16 which delimits a recessed inner surface 17.

[0062] A reference template 18, e.g. shaped as shown in FIG. 8, isarranged, in use, on the recessed surface 17.

[0063] The reference template 18, which can be made of aluminum, steelor plastics, has an external supporting frame 19, which is common to allkinds of template, and a locating grid 20 which instead varies accordingto the shape to be given to the module 1.

[0064] In the specific case shown in FIG. 8, the locating grid 20 has aseries of ribs 21 which reproduce the shape of a left module 22, shownin FIG. 7, of a composition shaped like a contrasting arc 60, shown inFIG. 6, thereby delimiting spaces 23 within which the blocks or tesserae24, shown in FIG. 1, are to be arranged.

[0065]FIG. 4 illustrates a locking cover 25 which is constituted by anouter border 26 delimiting a central opening 27 which is smaller thanthe recessed surface 17 of the template supporting tray 8.

[0066] The outer border 26 has, at its four corners, wider regions 28 atwhich there are provided through openings 29 arranged to act as femaleelements in coupling with the locating pins 12 when the locking cover 25is superimposed, in use, on the transfer tray 6.

[0067] On each shoulder 30 and 31 of the border 26 there is a lockingdevice 32 of the type shown in FIG. 5, which is constituted by a pair ofrods 33 and 34 which are aligned and fitted on a respective shoulder bymeans of brackets 35 and free to perform small straight strokeslengthwise.

[0068] The rods 33 and 34 are connected, at their ends, by a spring 36which has a central supporting cylinder 37 which is designed to keepthem at a predefined distance.

[0069] In order to use the locking device 32 it is necessary to move therods 33 and 34 mutually closer, thus overcoming the urge of the spring36 and, once the locking cover 25 has been placed on the templatesupporting tray 8, release them so that the outward ends 38 of the twowedge-shaped rods 33 and 34 interact with the rack-shaped front 13 ofthe respective facing locating pins 12, thereby preventing any upwardmovement of the cover 25.

[0070] As shown in FIG. 1, a movable unit 5 is prepared in theworkstation 40 of the apparatus 2 and is initially constituted only bythe transfer tray 6 and the template supporting tray 8.

[0071] An operator 41 can thus arrange on the template supporting tray 8a reference template 18 which is suitable for providing a module such asthe module 22 of FIG. 7.

[0072] The same operator 41 can deposit the blocks 24, available incontainers 42 located in the vicinity of the workstation 40, inside thegrid 20, by placing them with their bottom upward and trying tocompletely fill the spaces 23 delimited by the ribs 21 that constitutethe grid 20.

[0073] After blocks 24 have been placed on the template 18, the operator41 can also be given the task of cleaning the bottom of the blocks 24 ofany impurities that might be present. For cleaning the blocks 24 it ispossible to use a rotating brush with steel bristles 43, which islocated near the workstation 40 within reach of the operator 41.

[0074] Alternatively, the same cleaning operation can be performed bysubjecting the blocks 24 to a jet of water under pressure; in this caseit is necessary to perform a subsequent drying step, e.g. by employingjets of hot air; this solution is not shown in FIG. 1.

[0075] While the movable unit 5 is still located in the workstation 40,a primer 44 is advantageously sprayed onto it; said primer includes forexample a petroleum resin and/or rosin applied in a solvent phase and isdesigned to increase bonding of an adhesive material on the bottom ofthe blocks 24. This operation, too, can be performed manually by theoperator 41 or by a suitable primer dispensing device (not shown in FIG.1).

[0076] The operator 41 then places on the template 18, and therefore onthe blocks 24 arranged therein, a piece of net 45 cut beforehand so asto have the same configuration as that of the module being produced andlarger dimensions than said module, so as to protrude from its contourto a predetermined extent.

[0077] In order to complete the preparation of the movable unit 5, thelocking cover 25 is arranged on the template supporting tray 8, byinserting the pins 12 of the transfer tray 6 inside the through openings29 of the cover 25. In this manner, the frame 26 of the locking cover 25locks the template 18 on the template supporting tray 8 owing to the twolocking devices 32.

[0078] Once the preparation of the movable unit 5 has been completed,the operator 41 arranges it on the initial station 46 of the conveyor 4,which by being controlled by a control unit 47 transfers it sequentiallythrough a series of workstations according to a predefined productioncycle.

[0079] Preferably, the conveyor 4, controlled by a control unit 47,causes a given module 1 being produced to pass through a drying device48 provided with hot air jets, not shown in FIG. 1, so as to ensure fulldrying of the primer 44 and heating of the material to the temperaturesuitable for the subsequent glueing step.

[0080] Once the drying step is terminated, the control unit 47 sends acontrol signal for the advancement of the movable unit 5 to theworkstation 49. Once the movable unit 5 has reached the workstation 49,a device 50 for applying permanent securing means is energized in orderto rigidly secure the net 45 to the bottom of the blocks 24.

[0081] Preferably, a dispenser 50 of an adhesive material is used whichis equipped with a metering device (not shown) and is mounted onsuitable mechanical arms 52 and 53 which can freely move, upon control,along two perpendicular directions X and Y.

[0082] In this manner, adhesive material, which can be for example ofthe hot-melt type including EVA (Ethyl Vinyl Acetate) and syntheticresins or synthetic adhesives, is deposited at preset points uponcontrol of the control unit 47 and are usually distributed so as tosecure the net 45 at its nodes 54 to the bottom of the blocks 24.

[0083] Advantageously, a step is provided for drying the freshlydeposited adhesive material; in this case, the module 1 being producedis forwarded to another drying device 56 e.g. provided with a series ofhot air jets (not shown).

[0084] The production cycle at this points provides for the advancementof the movable unit 5 to the workstation 57, where an operator 58 hasthe task of checking the quality of the finished product and, should themodule 1 meet predefined characteristics, transferring it to a conveyorbelt 59 which discharges into a store.

[0085] Transfer of the finished module 1 from the workstation 57 to theconveyor 59 can be performed manually by the operator 58, who canoverturn it in order to prepare it for the subsequent step of packagingor storage.

[0086] As shown in FIG. 7 and in FIGS. 9 to 23, a generic module 1 canbe composed of blocks or tesserae 24 made of porphyry, granite or otherstone-like or artificial materials.

[0087] In the specific case of module 22 in FIG. 7, which illustratesthe left module of a composition shaped like a contrasting arc 60 shownin FIG. 6, it will be noted that the blocks 61 that are designed tooccupy, in use, positions at the center of the composition 60 are largerthan the lateral ones 62.

[0088] Moreover, module 22 of FIG. 7 and modules shown in FIGS. 9 to 14have a step-shaped side 63 which is designed to delimit, in use, one ofthe two lateral edges of the contrasting arc composition 60; twoadjacent modules which belong to two nearby arcs 60 are thus coupled byarranging the corresponding lateral edges 63 side by side, therebypenetrating each other so as to ensure a self-locking effect in additionto uniformity of the finished work.

[0089] So far as the module 22 of FIG. 7 and to those of FIGS. 9 to 13are concerned, the lateral saw-tooth edge 64 which is opposite to thestep-shaped edge 63 is constituted by an alternation of recesses 65 andprotrusions 67 which is studied so as to allow to combine them byinterlocking in pairs, i.e., the left module 22 with the right one 68,the left initial module 69 with the right one 68, the right initialmodule 70 with the left one 22, the left final module 71 with the rightone 68, and the right final module 72 with the left one 22. The lateralmodule 95 of FIG. 14 instead has a straight lateral edge 96 which isopposite to the step-shaped one 63, since it acts as an element fordefining the border of the surface to be covered.

[0090] If the composition is circular, like the composition 73 shown inFIG. 15, the module 74 of FIG. 16 is a single one and represents aquarter of a circle. The module 74 is constituted by a sequence ofconcentric circular arcs 75 formed by blocks 24 whose dimensionsdecrease towards the center of the circle. There is also an angularmodule 76 and two lateral modules, a left one 78 and a right one 79, asshown respectively in FIGS. 17, 18 and 19.

[0091] The composition shaped like a compound fan 80 of FIG. 20 iscomposed of two lateral modules, a left one 81 as in FIG. 21 and a rightone 82 as in FIG. 22, and a central module 83 of FIG. 23.

[0092] The standard central module 83 shown in FIG. 23 can in turn beconstituted by two modules which represent, respectively, its left half84, shown in FIG. 24, and its right half 85, shown in FIG. 25.

[0093] A second embodiment of the fan-shaped composition 80 isconstituted only by two modules, a left one 86 and a right one 87, shownrespectively in FIGS. 26 and 27, each of which already includes the lefthalf 84 and the right half 85 of the central module 83, respectively.

[0094] The left and right final prefabricated modules 89 and 90 and theleft and right lateral closure modules 91 and 92, shown respectively inFIGS. 28, 29, 30 and 31, are common to both of the embodiments of thefan-shaped composition 80.

[0095] The method and the apparatus for producing prefabricated modulesfor paving and/or panelling are susceptible of numerous modificationsand variations within the scope of the protection defined by the contentof the appended claims.

1. A method of manufacturing modules for paving and/or panelling,comprising the following operating steps: arranging a plurality ofblocks or tesserae (24) in a suitable template (28), according to apredetermined layout defined by a locating grid (20) delimiting a module(1); cutting out a piece of a layer (45) of flexible material havingthrough openings so as to match the configuration of said module (1) andbeing of larger dimensions than said module (1); securing, by means ofpermanent securing means (12) said layer (45) of flexible material toeach one of said blocks or tesserae (24) forming said module (1), sothat they are held together by said piece (45) of flexible material withthe possibility of changing their mutual inclination.
 2. The methodaccording to claim 1, characterized in that said blocks (24) arearranged on said template (18) with their bottom facing upwards.
 3. Themethod according to claims 1 or 2, characterized in that said piece (45)of flexible material is placed on said blocks (24).
 4. The methodaccording to claim 3, characterized in that a locking cover (25) issuperimposed on said template (18) and acts as a complementary template,so as to lock said blocks (24) on said template (18) and keep said piece(45) flat on said blocks
 24. 5. The method according to claim 1,characterized in that said piece (45) of flexible material is providedwith through openings and coupled to the bottom of each one of saidblocks (24) by means of adhesive material.
 6. The method according toclaim 5, characterized in that it comprises, before securing said piece(45) of flexible material to said blocks (24), spraying and drying aprimer on the bottom of said blocks (24) in order to promote adhesion ofsaid adhesive material to the bottom of said blocks (24).
 7. The methodaccording to claim 6, characterized in that it comprises a drying stepin order to accelerate setting of said adhesive material.
 8. The methodaccording to any one of claims 6 or 7, characterized in that itcomprises an initial step of cleaning said blocks (24) in order toensure better adhesion of said primer to the bottom of said blocks (24).9. The method according to any one of the preceding claims,characterized in that it comprises, once said piece (45) has beensecured to the bottom of said blocks (24), removal of said locking cover(25) from said template (18).
 10. An apparatus for performing the methodaccording to any one of the preceding claims, having a supporting frame(3), a plurality of sequentially arranged workstations (40,48,49,56,57)and a conveyor (4) which extends sequentially through said workstations(40,48,49,56,57), and characterized in that it comprises at least onemovable unit (5) which can be arranged on said conveyor (4) in order topass a module (1) through each one of said workstations(40,48,49,56,57), and in that one (49) of said workstations comprises adevice for applying permanent coupling means in order to secure a piece(45) of flexible material to the bottom of said module (1).
 11. Theapparatus according to claim 10, characterized in that said movable unit(5) comprises a movable transfer tray (6) which is designed to bearranged on said conveyor (4); a template supporting tray (8) to bearranged on said movable transfer tray (6), at least one referencetemplate (18) which can be fitted on said template supporting tray (6),and a locking cover (25) designed to fix the or each reference template(18) onto said template supporting tray (6).
 12. The apparatus accordingto claim 11, characterized in that said reference template (18)comprises a grid (20) which is shaped according to the intendedcomposition, thereby simplifying the operation of laying blocks ortesserae (24) on said reference template (18) in order to form saidmodule (1).
 13. The apparatus according to claim 11 or 12, characterizedin that said cover (25) acts as complementary template for the or eachreference template and can be superimposed thereon so as to lock saidblocks (24) inside said grid (20) and keep said piece (45) of flexiblematerial spread flat over said blocks (24).
 14. The apparatus accordingto any one of claims 10 to 13, characterized in that said device forapplying permanent securing means comprises a metering device foradhesive material.
 15. The apparatus according to claim 14,characterized in that it comprises a relative movement between saidmetering device and said movable unit (5) to distribute said adhesivematerial on the bottom of each one of said blocks (24) forming saidmodule (1).
 16. The apparatus according to claim 14 or 15, characterizedin that said dosage device for adhesive material is movable with respectto said movable unit (5) in two mutually perpendicular directions. 17.The apparatus according to any one of claims 14 to 16, characterized inthat downstream of said dosage device there is provided a drying station(48), so as to accelerate drying of said adhesive material.
 18. Theapparatus according to any one of claims 14 to 17, characterized in thatit comprises a device (43) for cleaning said blocks or tesserae (24).19. The apparatus according to claim 18, characterized in that saidcleaning device (43) comprises an apparatus for dispensing pressurizedliquid.
 20. The apparatus according to claim 19, characterized in thatit comprises a drying system downstream of said pressurized liquiddispensing apparatus.
 21. The apparatus according to claim 18,characterized in that said cleaning device comprises a series of brushes(43) which are suitable to eliminate during a dry process any impuritiespresent on the bottom of said blocks (24).
 22. The apparatus accordingto any one of claims 10 to 13, characterized in that said device forapplying permanent locking means comprises at least one applicator ofmechanical retention elements.
 23. A module for street paving and/orcladding according to any one of the preceding claims, comprising atleast one block or tessera (24), characterized in that it comprises alayer of flexible material (45) provided with through openings and means(12) for permanent coupling between the or each block or tessera (24)and said layer (45) of flexible material.
 24. The module according toclaim 23, characterized in that said layer (45) of flexible material isconstituted by a net.
 25. The module according to claim 23 or 24,characterized in that it comprises two or more units of said block ortessera (24) which are arranged according to a chosen composition andare held together by means of said net (45) with the possibility ofchanging their mutual inclination.
 26. The module according to any oneof claims 23 to 25, characterized in that said net (45) is cut so as tohave the same shape as said module (1) and be larger than said module(1).
 27. The module according to any one of claims 23 to 26,characterized in that said permanent coupling means comprise adhesivematerials.
 28. The module according to claim 27, characterized in thatsaid adhesive materials comprise a hot-melt adhesive based on EVA (EthylVinyl Acetate) and synthetic resins or synthetic adhesives.
 29. Themodule according to any one of claims 23 to 26, characterized in thatsaid coupling means comprise mechanical retention elements.
 30. Themodule according to claim 29, characterized in that said mechanicalretention elements comprise at least one staple.
 31. The moduleaccording to claim 29, characterized in that said mechanical retentiondevices comprise at least one rivet.
 32. The module according to claim29, characterized in that said mechanical retention elements comprise atleast one screw anchor.
 33. The module according to any one of claims 23to 32, characterized in that it comprises a plurality of configurationsfor said module (1) which are combined in order to form a pattern orcomposition which is repeated identically a number of times whichdepends on the dimensions of the surface to be covered.
 34. The moduleaccording to claim 33, characterized in that said pattern or compositionis shaped like a contrasting arc.
 35. The module according to claim 33,characterized in that said pattern or composition is shaped like acircle.
 36. The prefabricated module according to claim 33,characterized in that said pattern or composition is shaped like acompound fan.